Welding system



April 27, 1948. J, w, DAWSQN 2,440,247

WELDING SYSTEI Filed Jan. 23, 1942 IMPUILSE 3 0 AAA\A Ah /0a 8 If" V3171 f 4,, 7 I

11a '6 Z W 2 Hahn W17 6070 I Patented Apr. 27, 1948 W ELDING' SYSTEM John W. Dawson, Auburndale, Mass, asslgnor to Raytheon Manufacturing Company, Newton, Mass., a corporation 01' Delaware Application January 23, 1942, Serial No. 427,897

11 Claims. 1

This invention relates to resistance welding systems in which the welding load receives current through a transformer'having a magnetic core, a pulse of current being supplied to the primary of the transformer of each weld. In such systems, particularly where each pulse of current supplied to the primary winding has a considerable direct current component, the problem of saturation of the transformer core, due to residual flux, becomes particularly troublesome. Such sequences of substantially unidirectional current impulses, however, are advantageous in resistance welding and can conveniently be provided by condenser discharges. as described and claimed in my copending application, Serial No. 309,124,fi1ed December 14, 1939, on Condenser welding systems.

One of the objects of this invention is to provide an arrangement controlled by electric valves derived from the welding energy impulses themselves, which supplies direct current to the transformer during time periods best suited for resetting the residual fiux apt to lead to saturation of the transformer core, to a value opposite that of the effective welding flux.

Another object is to provide an arrangement of the foregoing type in which pitting oi the work,

caused by arcing as the electrodes leave is substantially eliminated.

In one aspect of the invention, the maximum resetting mmf. is applied up to the very instant when the welding energy pulse begins to flow, so that it becomes more easily possible to base the operatively eiiective magnetic action of the transformer on the resetting flux which may reach a negative value having an absolute magnitude as high as that of the positive flux during welding. Therefore, since the effective flux capacity is the sum of the negative and positive components, this effective flux can be greatly increased and therefore the weight of the transformer considerably reduced.

In another aspect, the source of resetting current, as for example rectifier tubes, may have a comparatively low current rating since, according to the invention, that current can be held during the selected time period at its desired value without substantially exceeding that value.

In a further aspect, the resetting current is applied to the transformer through an appropriate networi: timing it directly in dependence upon the configuration of the transient weldin energy impulses and avoiding any possibility of improper fluctuation of the flux resetting energy.

In still another aspect of the invention, the resetting current is applied from a grid controlled rectifier arrangement whose conductivity is controlled directly by the voltage transient in the welding transformer primary,

The foregoing and other objects and aspects of this invention will be best understood from the the work,

following description, by way of example, of two practical embodiments thereof, reference being had to the accompanying drawings, wherein:

Fig. 1 is a diagram or a resistance welding sys tem embodying my invention;

Fig. 2 is a diagram of a modification of the circuit according to Fig. 1; and

Fig. 3 is a diagram representing electrical phenomena which occur during the operation of arrangements according to Figs; 1 and 2.

In the arrangement shown in Fig. i, welding current is to be supplied to a pair of welding electrodes i, Z forming the output circuit of the secondary winding 3 ct a welding transformer t. This welding transformer has a magnetic circuit represented by core member The primary winding t or the transformer is adapted to be energized by discharges from a relatively large condenser "i charged from a suitable source oi direct current.

in Fig i the direct current is shown as being supplied to the input terminals S and T of transformer from the condenser l charged from a pair of rectifier tubes 8 which may be of the gas or vapor filled type having permanently ener= gized cathodes Q connected through an impedance it to condenser and anodes iii connected to the terminals the secondary wind,- ing it of a charging transfer or it. charging transformer has a primal winding con nected at terminals id to a suitable source of alternating current. The transformer secondary i i is provided with a center tap G6 which is connected through a conductor all to the other terminal I i of condenser The impedance has a value selected to main .in the M 1 1 h re'- im; rate for condenser E".

Condenser terminal 3? is also rectly to the anode of discharge tube i9. This tube :1 pool cathode type wit .iiter a cathode spot on. 't ord any suitable type of igniter may be i" is preferably of the opending apt e c Eerie." No. now Patent Number plieation of Percy L. to filed November 3.3, l 2,290,897, for an im devices, namely con ting of a conductor separated and insulated from the cathode by a thin lass layer. The 26 of tube i is connected directly to one side S of the primary winding by means of a conductor The other side T of the primary winding is connected through conductor t'i the other side It? of condenser l.

A tube 23 preferably 01 the same type as tube it with anode pool. cathode 26 and electrostatic igniter 21 is connected between conductors il and 22 directly across the transformer primary I 3 6; cathode 28 is connected to conductor 22 while anode 25 is connected to conductor II.

The tube I9 is normally non-conducting, and therefore condenser I retains its charge until tube 19 is ignited. Its igniter 2i is at 28 supplied with igniting impulses from a transformer, for example upon closing a push button switch 38, as described in my copending application, Serial No. 312,019, filed January 2, 1940, now Patent Number 2,294,388. In order to assist the tube in startin a resistance in series with a condenser (not shown) may be connected across the tube, as described in the copending application of Wilcox P. Overbeck, Serial No. 271,679, filed May 4, 1939, now Patent Number 2,270,601.

The tube 23 which is likewise normally nonconducting is ignited at the proper time from an igniting transformer 31 having a secondary 38 connected between igniter 27 and cathode 28. The primary winding 39 of transformer 31 is connected across a voltage dividing resistance 40 which is connected in series with a rectifying tube 4i across the condenser I. The rectifier tube 4| is provided with a permanently energized cathode 42 connected to the positive terminal P, the condenser I, and with an anode 43 connected through resistance 40 to negative terminal N. The voltage across the tube 4| therefore corresponds to the voltage on the condenser I. Since the condenser 7 is charged from rectiflers 8 so that the left-hand sid is positive and the righthand side negative (as indicated by letters P and N) tube 4! ordinarily does not conduct current.

The welding electrode 2 is usually stationary while the conductor I is movable toward and away from the stationary electrode. This motion may be produced by any suitable arrangement, for example such as described in my above copending application.

When the system is energized, the condenser I acquires a charge as previously described. The electrodes l and 2 may then be closed upon a piece of work 52 tobe welded. Thereupon the igniting impulse is supplied to igniter 2i, for example by depressing push button 38. This causes the tube ill to start conducting current permitting con-' I magnetic retentivlty, the core would normally be denser 7 to supply a pulse of welding current to primary winding 8, and thus to the welding electrodes l and 2. This discharge of condenser I causes the voltage thereacross to fall to zero approximately when or shortly after the maximum discharge current is flowing. Thereupon the voltage across the condenser 1 tends to reverse whereas the current tends to continue to flow in the same direction due to the inductance of the various parts of the system to which the condenser I is connected.

As the voltage across condenser I reverses, the tube 4! will start to conduct current limited in amount by resistance 40 and a short pulse of current will flow through resistance 40, setting up a voltage which is supplied to the primary winding 39 and supplies an igniting impulse to the igniter 21. Thereupon the tube 23 becomes ignited and the current instead of flowing through the condenser I and tube I9 flows through tube 23. .As described and claimed in my above copending application, this causes substantially exponential decay of the welding current and substantially unidirectional current flow in the primary winding 6, for eaclr welding impulse.

denser Fbeing recharged while welding current is still flowing in the welding load. The above arrangement is therefore particularly advantageous at high welding speeds. of course it is to be understood that the welding electrodes and switch 38 may be automatically operated so as to control timing and speed of the individual welding operations.

Since a substantially unidirectional pulse of current is supplied to the primary winding 6 for each weld and since the core member 5 has some left with a residual magnetic flux (herein referred to as positive flux) at the end of each weld. Subsequent welding operations would tend to increase this flux so that the core would soon become saturated. For the purpose of resetting this flux between welds and for other above indicated purposes, the following arrangement is provided according to my present invention.

Such an arrangement may include a pair of rectifier tubes BI, 62, preferably of the gas filled type and having permanently energized cathodes 63, 64, anodes 65, 66 and control grids 67, 68. Anodes and 66 are connected to respective terminals of secondary I2 of a transformer I0 whose primary II is supplied from a suitable alternating current source, for example transformer I2. A midpoint tap 80 of transformer I0 is connected to a point 2) between a resistance 82 and a condenser 83 connected across primary 5 of welding transformer 4.

The cathodes 63, 54 of tubes BI, 62 are connected to a midpoint tap M of transformer 4, which tap is connected to transformer terminal T through resistance constituting a voltage apportioning device.

The grids GI, 68 of tubes 6!, 62 are connected through an impedance 9i having a midpoint 92 which is connected to an adjustaible tap g of resistance 90. Impedance 9! may form the secondary of a transformer whose primary 96 is supplied with alternating current having a certain phase relationship to the alternating current supplied to transformer I0, as will be described in detail hereinbelow. Two resistances 93 are preferably inserted between secondary 9i and grids 67, B8, and two condensers 94 are connected between grid and cathode of tubes SI, 62.

The above-described arrangement operates as follows:

Referring to Fig. 3, the main condenser I will begin to discharge at time a, when tube i9 is rendered conductive by applying at 28 an igniting impulse. The direction of the discharge is indicated in Fig. l by arrows t. The condenser voltage decreases while the welding current Iw increases, as shown in the upper diagram of Fig. 3 which indicates current values. During the condenser discharge, the voltage E'r of transformer terminal T goes from negative towards more positive values, and the voltage Es of terminal S towards more negative values, as indicated in the lower diagram of Fig. Z which indicates voltage .5 values related to the potential of midpoint M as zero axis.

The impedance of condenser 83 is low as compared with that 01 resistor 82 so that the voltage of point 1 between resistor 82 and condenser 83, which voltage is initially on the negative side,

will, due to the effector condenser 83, quickly change towards the positive, as indicated at Ep. It will be noted that EM is the voltage applied to cathodes B3, 64 of tubes GI, 62, and Ep the voltage applied to anodes 65, 68 of these tubes. Therefore, from time b 'where Ep intersects EM, cathodes 63, 64 are more negative than anodes 65, 86, and tubes GI, 62 are ready to fire. The grids 51, 6B are supplied with a voltage Es derived from tap o of resistance 80 which, in the absence of condenser Hlil is proportionate to but more negative than the voltage of point M, so that tubes Bi, 62 are as yet prevented from becoming conductive.

Still assuming that the condenser Hill is not incorporated in the circuit, the voltage applied to grids 81, 68 can be so adjusted by means oi tap g that the grids are sufficiently positive and the tubes BI, 62 begin to fire at a time when the welding current is approximately at its peak value. From here on, the tubes iii, 62 supply rectified current In in the direction of arrow r in Fig. 1, flowing through the windings of primary 8 between points M and S and hence setting up in the transformer core a magnetic flux opposite to that due to the welding current l'w. It will be noted that the condenser 83 prevents flow of resetting current through primary half MT.

At time d, the main transformer voltage goes in the other direction. It will be noted that, between 0 and d, the rectifier tubes carry a com ponent of the main circuit current as well as their own rectified current. Although this period is very short so that there may be no danger or overloading rectifier tubes selected to carry the current required for flux resetting, it may be desirable to modify the grid voltage control as follows.

A condenser I00 may be connected between a point of resistance 90 and transformer midpoint M which is Joined to cathodes 83, 66. This condenser aifects the voltage at tap $2 of grid impedance 95' by first subtracting from and later adding to and delaying the change of voltage E's towards more positive values; this modified configuration of E3 is indicated at E's of Fig. 2 and can be controlled, according to well known principles, by appropriately relatin the capacity of condenser W0 and the resistance distribution between taps g and With the grid voltage controlled in this manner, the tubes 6t, 52 can be prevented from firing well beyond time at, so that they will never carry any current other than that supplied thereto from transformer iii.

In Fig. 3, the current and voltage transients obtained without condenser we are indicated by dotted lines whereas the values derived irom a network including an element corresponding to condenser Hill are drawn in full lines.

At time e, the current tube 23 fires, the exponentially decaying welding current flows are in dicated by arrow s, and the voltage across the transformer will be very slight corresponding to the drop of tube 23. The grids of tubes iii 62 are now safely positive, the anodes and cathodes of these tubes are not adversely affected by the conditions prevailing in the main circuit and rectifled current is supplied to hall of the main transformer in the circuit 99-M-S82-p8fi, in

direction r opposite to the welding current flowing in direction it.

At the beginning 01- a new welding cycle at a, l

the transformer voltage distribution again remders the anodes 65, 66 more negative tha the cathodes 63, B as above described, and the ilux resetting current Ia ceases to flow at a.

In this way the residual flux in the core member ii is eliminated and the tendency for subsequent welding operations to saturate said core prevented. Although resetting of the residual flux to a. zero value will eliminate any tendency for saturation, I prefer to supply from the rectifiers SI, 52 direct current or a value sufilcient to set up in the transformer core a flux of opposite direction to the residual flux. As mentioned above, this arrangement provides greater elliciency of utilization of the core material so that the transformer d can be made with a much smaller core. This advantage increases with the value of the reverse flux until it is at the beginning of the succeeding weld substantially equal to the maximum flux in the opposite direction durin an actual weldin operation. It will be understood that the flux resetting current must not necessarily be applied to the welding transformer primary, but can be used to set up the required flux in a different way, for example by means of a separate winding.

In order to enable the grids ill, 58 to assume control for preventing with certainty the firing of tubes BI, 62 when the anode voltage is applied at time b, it is advantageous to use tubes, as thyratrons, with very short delonization time. In order to assure that these tubes will fire as soon as the voltage at tap g has reached the intended value, this voltage is superimposed on an alternating current voltage applied to grids El and 68 through winding 9i constituting the secondary or transformer 3&3. To accomplish this purpose, the alternating current supplied to transformer .95 has a voltage which leads the voltage supplied to plates 6d. 66 about for the purpose of rendering the grid voltage a maximum near the time when the critical grid potential is high at the beginning of the positive anode potential half wave.

In welding systems in which the present invention is not used, a number of welding current pulses will produce at least partial saturation. Thereupon another welding current pulse will cause the flux to rise to relatively high levels, raising that flux to regions in which saturation is definitely present. A flux in a saturated core has a tendency to collapse very quickly when the exciting magnetomotive force is removed. Such collapse induces currents of inverse sign in the secondary winding of the transformer. This inverse current will be flowing at the time the electrodes leave the work, thus causing pitting. The resetting of the flux in accordance with the presei'it invention occurs at a relatively slow rate, and maintains the flux at a value opposite that of the main welding flux between welding impulses. This eliminates saturation and the pitting as described above.

It will now be evident that the direct current component for the resetting flux need not necessarily be supplied from a rectifier arrangement as shown in Fig. l but from any convenient current source, so long as the application of that component is controlled by the configuration of the welding energy impulse itself. Under certain conditions it may be advantageous to eliminate any alternating current ripples from the resetting current and to supply essentially smooth resetting current. For that purpose, an arrangement indicated in Fig. 2 may be used.

In Fig. 2 the essential elements of a weldin circuit are indicated with the numerals of corresponding elements in Fig. 1. However, instead of transformer III with rectifier tubes 8!, 62, an independent direct current supply is indicated by terminals iill, I02 which may, for example, be connected to a generator or to a multi-anode rectifier arrangement with filter circuit, which well known direct current sources are not shown in Fig. 2. The direct current supplied at vlill, I02 has a polarity adapted to eiTect the required rcsetting fiux.

Terminal IUI is connected to point 1; between resistance 82 and condenser 83, whereas terminal I02 is connected to anode H5 of a control tube I I whose cathode I I3 is joined to midpoint M of main transformer primary 5. As in Fig. I, resistance 90 is connected between points M and T. The grid Il'l of tube H0 is supplied with control voltage from tap g of resistance 90; a condenser I00 may again be provided in order to delay the change of the grid voltage towards more positive values, and alternating current voltage may be superimposed by means of transformer 95.

The voltages at points M, p and g, and hence at cathode H3, anode H5 and grid ill will be those indicated at EM, Ep and E; (or E's) of Fig. 3, and the resetting current I'a has the general configuration of current Ia, with the difference that it will be essentially smooth as indicated in Fig. 3.

It will further be evident that arrangements of which those above described are examples can not only be applied to welding systems other than those herein described, but to arrangements presenting similar control problems.

It should be understood that the present disclosure is for the purpose of illustration only and that this invention includes all modifications and equivalents which fall within the scope of the appended claims.

What is claimed is:

1. An electric control system comprising a transformer having an input winding with two supply terminals, an intermediate terminal, an output winding and a magnetic circuit coupling said windings, means for supplying to said wind- .ings a current impulse with an ascending and a voltage apportioning means connected between said intermediate terminal and one of said supply terminals, a current source having terminals supplying a voltage difference, electronic valve means having cathode means connected to said intermediate terminal, anode means connected in series with said source terminals to a point between said resistance and said condenser, control electrode m ans connected to a point of said apportioning means.

2. electric control system comprising a transformer having an input winding with two supply terminals, an intermediate terminal, an output winding and a magnetic circuit coupling said windings, means for supplying to said windings a current impulse with an ascending and a decaying period and having a unidirectionally operative component. a resistance and a capacitance connected in series between said input terminals,

voltage apportioning means connected between said intermediate terminal and one of said supply terminals, 9. source having terminals supplying an diate terminal, anode means connected in series with said source terminals to a point between said resistance and said condenser, and control electrode means connected to a point of said apportioning means.

3. An electric control system comprising a transformer having an input winding with two supply terminals, an intermediate terminal, an output winding and a magnetic circuit coupling said windings, means for supplying to said windings a current impulse with an ascending and a decaying period and having a unidirectionally operative component, a resistance and a capacitance connected in series between said input terminals, voltage apportioning means connected between said intermediate terminal and one of said supply terminals, a source having terminals supplying a. direct current. electronic valve means having cathode means connected to said intermediate terminal, anode means connected in series with said source terminals, to a point between said resistance and said condenser, and control electrode means connected to a point of said apportioning means.

4. An electric control system comprising a transformer having an input winding with two supply terminals, an intermediate terminal, an output winding and a magnetic circuit coupling said windings, means for supplying to said windings a, current impulse with an ascending and a decaying period and having a 'unidirectionally operative component, a resistance and'a capacitance connected in series between said input terminals, voltage apportioning means connected between said intermediate terminal and one of said supply terminals, a current source having terminals supplying a voltage difference, electronic valve means having cathode means connected to said intermediate terminal, a condenser connected between said cathode means and a point of said apportioning means, anode means connected in series with said source terminals to a point between said resistance and said condenser, and control electrode means connected to a point of said apportioning means.

5. In combination, an alternating current sup- 5 ply circuit, a load circuit, transforming means having a magnetic core member, primary winding means and secondary winding means connected to said load circuit, normally nonconducting electric valve means connected between said supply circuit andsaid primary winding means, normally conducting second electric valve means poled in opposition to the first mentioned electric valve means and connected between said supply circuit and said primary winding means for transmitting current through said primary winding means in a direction opposite to that eflected by said first mentioned electric valve means and at times immediately preceding the interval of conduction by said first mentioned electric valve means and for controlling the current to presaturate said transforming means, means for rendering the first mentioned electric valve means conducting and for rendering said second electric valve means non-conducting thereby efiecting the transmission of an impulse oifcurrent to said load circuit, and electric valve means connected to said primary winding means and poled to provide a path for the fiow of current incident to the electromagnetic energy stored in said transforming means occasioned by conduction of said first mentioned electric valve means thereby permitting the current transmitted to said load circuit to decay exponentially.

6. In combination, an alternating current supply circuit, a load circuit, transforming means having a magneticcore member, primary winding means and secondary winding means connected to said load circuit, electric valve means connected between said supply circuit and said primary winding means, control means for said electric valve means, a second electric valve means poled in oppositionto the first mentioned electric valve means, control means for controlling said second electric valve means to transmit current through said primary winding means in a direction opposite to that eifected by said first mentioned electric valve means and at times immediately preceding the interval of conduction by said first mentioned electric valve means and for controlling the current transmitted by said second electric valve means to pre-saturate said transforming means and for controlling the wave form of the current supplied to said load circuit, and electric valve means connected to said primary winding means for providing a path for the now of current due to the electromagnetic energy stored in said transforming means occasioned by conduction of said first mentioned electric valve means.

'7. In combination, an alternating current supply circuit, a load circuit, transforming means having a magnetic core member, primary winding means and secondary winding means connected to said load circuit, normally nonconducting electric valve means connected between said supply circuit and said primary winding means and being of the type employing an ionizable medium capable of supporting an arc discharge, means for pre-saturating said magnetic core member in a direction opposite to the magnetization effected by the flow of current through said electric valve means, means for rendering said electric valve means conducting and for transmitting current to said primary winding means from said alternating current circuit, and unidirectional conducting means connected to said primary winding means for providing a path for the flow of cur ent incident to the electromagnetic energy stored in said transforming means occasioned by the conduction of current by said electric valve means'and for causing the decay of current exponentially in said load circuit.

8. In combination, an alternating current supply circuit, a load circuit, transforming means having a magnetic core member, primary winding means and secondary winding means connected to said load circuit, normally 'nonconducting electric valve means connected, between said supply circuit and said primary winding means and being of the type employing an ionizable medium capable of supporting an arc discharge, means for premagnet'izing said magnetic core member to a point of saturation and in a direction opposite to the magnetization effected by the flow of current through said electric valve means, means for rendering said electric valve means conducting and for transmitting current to said primary winding means from said alternating current circuit, and unidirectional conducting means connected to said primary winding means for preventing the transfer of stored electromagnetic energy of said transforming means incident to the flow of current through said primary winding means to said supply circuit. a

9. In combination, an alternating current supply circuit, a load circuit, transforming means having a magnetic core member, primary winding means and secondary winding means connected to said load circuit, normally non-conducting electric valve means connected between said supply circuit and said primary winding means and being of the type employing an ionizable medium capable of supporting an arc discharge, means for pre-saturating said magnetic core member in a direction opposite to the magnetization effected by the flow of current through said electric valve means, means for rendering said electric Vail-i: zmeans conducting and for transmitting current to said primary winding means from said alter nating current circuit, and unidirectional conducting means connected to said primary winding means to extend the duration of the impulse of current transmitted to said load circuit.

10. In combination, an alternating current, supply circuit, aload circuit, transforming means having a magnetic core member, primary winding means and secondary winding means connected to said load circuit, normally nonconducting electric valve means connected between said supply circuit and said primary winding means and being of the type employing an ionizable medium capable of supporting an arc discharge, means for .pre-saturating said magnetic core member and in a direction opposite to the magnetization effected by the now of current through said electric valve means, means for rendering said electric valve means conducting and for transmitting current to said primary winding means from said alternating current circuit, and unidirectional conducting means connected to said primary winding means to prevent the inductance of said transforming means from extending the time of conduction of the electric valve means into the region where appreciable stored electromagnetic energy will be transferred from said transformingmeans to said supply circuit.

11. In combination, an alternating current sup-- ply circuit, a load circuit, transforming means having a magnetic core member, primary winding means and secondary winding means connected to said load circuit, normally nonconducting elec-- tric valve means connected between said supply circuit and said primary winding means and being of the type capable of supporting an are discharge, a premagnetizing circuit for said transforming means for establishing a unidirectional magnetization having a direction opposite to that effected by the flow of current through said electric valve means, control means for rendering said electric valve means conducting and for transmitting current to said primary winding means from said alternating current supply circuit, electric valve means connected to said primary winding means to extend the duration of the impulse of current transmitted to said load cir cult, and means responsive to said control means for controlling the conductivity of said last mentioned electric valve means.

JOHN W. DAWSON.

' REFERENCES CITED UNITED STATES PATENTS Name Date Lord June 14, 1938 Number 2,120,565 

